Current Situation and Future Trend of Automobile Mould Industry in China
发布时间：2018-09-05 浏览次数：1010次
According to statistics, at present, there are more than 30 automobile mold factories ( companies ) with a slightly larger scale in China, with more than 7,000 employees, including about 1,000 designers, manufacturers and managers, accounting for 14 % of the total number of employees. The original value of fixed assets in the whole industry is about 900 million yuan, the net value is about 700 million yuan, the annual sales income is about 4.4 billion yuan, the total labor productivity is about 450,000 yuan / person, and the annual manufacturing capacity is about 12 million man - hours, of which the manufacturing capacity of large and medium-sized molds is about 5 million man - hours / year. In particular, after the technological transformation during the " Ninth Five - Year Plan" period, not only the production capacity and output of the automobile mold industry have been improved, but also the product level and quality have been improved. For example, the solid mold casting technology for automobile body molds and the popularization and application of new air-cooled steel have played a positive role in improving the quality of automobile panel molds and reducing the machining workload.
At present, China is basically self-sufficient in molds such as trucks, light vehicles and minivans, and can produce some molds for car covers. However, most of the molds for cars still need to be imported, mainly the body panel molds and interior trim molds, with an annual import value of more than US $ 100 million.
China's automobile mold industry has developed rapidly and made great progress recently, but there is still a significant gap compared with foreign advanced level. The main performance is as follows:
First, the manufacturing accuracy is poor. Taking seals as an example, many people have reflected that the sealing performance of domestic cars is not good. In fact, this is not only related to the manufacturing level of sealing materials and seals, but also directly related to the level of relevant molds. At present, foreign automobile enterprises are implementing the " 2mm" project, but in our country, a single part can still be achieved, and there is no guarantee that hundreds of parts will be assembled together. The key lies in the mold.
Second, the die life is short. Take the aluminum die-casting die for example, foreign advanced level has reached more than 1 million times, while China has only 200,000 times, which is only 1 / 5 of foreign level.
Third, the mold development cycle is long. In the past, China's automobile models have remained unchanged for decades, and the development of automobile molds has been slow. With the fierce competition, the replacement of automobile products is speeding up and the mold industry is required to shorten the mold development cycle accordingly. At present, the development cycle of medium-sized die-casting dies in foreign countries is only 1 - 2 months, and the development cycle of automobile panel dies is 6 - 7 months, while in China it is 2 - 3 times the level in foreign countries. Therefore, although some of the more powerful automobile mold factories in China have the strength to develop new molds, they often lose their market competitiveness because they cannot keep up with the pace of the replacement of automobile products.
The main reason for the above problems is that the enterprise structure of China's automobile mould industry is unreasonable, and the gap between software development, management and personnel quality and foreign advanced level is large.
First, the degree of specialization and standardization is low. Internationally, automobile molds have entered the stage of specialization and standardization. Foreign automobile molds are basically provided by professional mold manufacturers, and the commercialization rate of molds is above 70 %. There are also many enterprises specializing in the production of mold standard parts, including hundreds of automobile mold standard parts. However, China's main mold production capacity is concentrated in the mold branch or workshop of each main machine factory, and the mold commercialization rate is low. Although the enterprise structure was adjusted during the Ninth Five - Year Plan period, the proportion of self-produced molds still reached about 70 %. In terms of standard parts for automobile dies, there are only two enterprises with a certain batch in our country.
Secondly, the design and manufacturing technology are backward. The most outstanding performance is the poor secondary development ability of the software. In recent years, China has introduced many foreign advanced mold design software. However, the data and materials of China's automobile products are different from those of other countries. Only by combining the introduction of software with China's national conditions can we design and manufacture molds that meet the market requirements. The main reasons for the weak secondary development ability of China's mold software are lack of development experience and weak technical strength.
The third is the low management level and personnel quality. In recent years, some major domestic automobile mold factories have successively introduced the world's advanced mold processing equipment, including FAW, Dongfeng, Tianqi, Chengfei and other four enterprises with fixed assets of about 200 million yuan, but the product performance and technical level are still significantly different from those of foreign advanced level, mainly due to the low management level and personnel quality, resulting in the low utilization rate of equipment and the failure to give full play to its performance.
The automobile mould market is very huge and can account for about half of the whole mould market in developed industrial countries. It is estimated that by 2005, there will be 170 kinds of basic automobile models in China, 430 kinds of updated and refitted automobile models, and there will be a great demand for automobile molds. In the next few years, the auto mold industry should focus on the following categories of products:
Die for large and medium-sized automobile covers. With the development of automobile to high speed, comfort and style, the structure of automobile body will become more and more complicated, requiring the development of mold to be large, complicated and high quality. It is estimated that from 2000 to 2005, the average annual demand for automobile body molds in China will be about 15 million man - hours, of which 9.36 million man-hours will be required for large and medium-sized molds. However, at present, China's large and medium-sized automobile mold production capacity is only 5.2 million man-hours per year, with a shortage of 4.36 million man-hours per year, and the satisfaction rate is only 53.4 %.
Plastic part mould. Driven by the trend of lightweight body, the application of plastics in automobiles has increased significantly, with the number of plastic parts and total weight of each automobile rising continuously. According to the calculation of the annual output of 3 million vehicles in 2005, China needs 300,000 tons of all kinds of plastic parts for automobiles, while the current production capacity is only 200,000 tons, and there is a great contradiction between production and demand. In particular, the large and medium-sized plastic molds required for manufacturing bumpers, instrument panels, fuel tanks, steering wheels, etc. are expected to meet only about 50 % of the planned demand in 2005.
Motorcycle mould. A motorcycle of one model needs nearly 1000 sets of moulds, worth more than 10 million yuan. China is already the world's largest motorcycle producer, with an annual output of more than 10 million motorcycles. Although most of the moulds for motorcycles can be produced in China, efforts should be made to nationalize the castings. Mould for agricultural vehicles. In the past, the mold industry did not pay enough attention to the molds of agricultural vehicles. In recent years, China's agricultural vehicle market has developed rapidly, with an annual output of more than 2 million vehicles, and the demand for molds has grown rapidly. At the same time, with the development of agricultural vehicles towards comfort, higher requirements have also been put forward for molds. During the " Tenth Five - Year Plan" period, the auto mold industry must pay enough attention to this market.
Conclusion
On the whole, China's low-tech molds are already in short supply and the market profit margin is narrow. However, the medium and high-grade molds with high technical content are still far from meeting the needs of economic development, and there is still much room for development of high-grade molds such as precision and complex dies and car cover molds. The future development direction of China's automobile mould industry should focus on the adjustment and positioning of product structure. To further improve the level of mold manufacturing technology and occupy the high-grade mold market with complex structure, high precision and high technical content.
At present, China is basically self-sufficient in molds such as trucks, light vehicles and minivans, and can produce some molds for car covers. However, most of the molds for cars still need to be imported, mainly the body panel molds and interior trim molds, with an annual import value of more than US $ 100 million.
China's automobile mold industry has developed rapidly and made great progress recently, but there is still a significant gap compared with foreign advanced level. The main performance is as follows:
First, the manufacturing accuracy is poor. Taking seals as an example, many people have reflected that the sealing performance of domestic cars is not good. In fact, this is not only related to the manufacturing level of sealing materials and seals, but also directly related to the level of relevant molds. At present, foreign automobile enterprises are implementing the " 2mm" project, but in our country, a single part can still be achieved, and there is no guarantee that hundreds of parts will be assembled together. The key lies in the mold.
Second, the die life is short. Take the aluminum die-casting die for example, foreign advanced level has reached more than 1 million times, while China has only 200,000 times, which is only 1 / 5 of foreign level.
Third, the mold development cycle is long. In the past, China's automobile models have remained unchanged for decades, and the development of automobile molds has been slow. With the fierce competition, the replacement of automobile products is speeding up and the mold industry is required to shorten the mold development cycle accordingly. At present, the development cycle of medium-sized die-casting dies in foreign countries is only 1 - 2 months, and the development cycle of automobile panel dies is 6 - 7 months, while in China it is 2 - 3 times the level in foreign countries. Therefore, although some of the more powerful automobile mold factories in China have the strength to develop new molds, they often lose their market competitiveness because they cannot keep up with the pace of the replacement of automobile products.
The main reason for the above problems is that the enterprise structure of China's automobile mould industry is unreasonable, and the gap between software development, management and personnel quality and foreign advanced level is large.
First, the degree of specialization and standardization is low. Internationally, automobile molds have entered the stage of specialization and standardization. Foreign automobile molds are basically provided by professional mold manufacturers, and the commercialization rate of molds is above 70 %. There are also many enterprises specializing in the production of mold standard parts, including hundreds of automobile mold standard parts. However, China's main mold production capacity is concentrated in the mold branch or workshop of each main machine factory, and the mold commercialization rate is low. Although the enterprise structure was adjusted during the Ninth Five - Year Plan period, the proportion of self-produced molds still reached about 70 %. In terms of standard parts for automobile dies, there are only two enterprises with a certain batch in our country.
Secondly, the design and manufacturing technology are backward. The most outstanding performance is the poor secondary development ability of the software. In recent years, China has introduced many foreign advanced mold design software. However, the data and materials of China's automobile products are different from those of other countries. Only by combining the introduction of software with China's national conditions can we design and manufacture molds that meet the market requirements. The main reasons for the weak secondary development ability of China's mold software are lack of development experience and weak technical strength.
The third is the low management level and personnel quality. In recent years, some major domestic automobile mold factories have successively introduced the world's advanced mold processing equipment, including FAW, Dongfeng, Tianqi, Chengfei and other four enterprises with fixed assets of about 200 million yuan, but the product performance and technical level are still significantly different from those of foreign advanced level, mainly due to the low management level and personnel quality, resulting in the low utilization rate of equipment and the failure to give full play to its performance.
The automobile mould market is very huge and can account for about half of the whole mould market in developed industrial countries. It is estimated that by 2005, there will be 170 kinds of basic automobile models in China, 430 kinds of updated and refitted automobile models, and there will be a great demand for automobile molds. In the next few years, the auto mold industry should focus on the following categories of products:
Die for large and medium-sized automobile covers. With the development of automobile to high speed, comfort and style, the structure of automobile body will become more and more complicated, requiring the development of mold to be large, complicated and high quality. It is estimated that from 2000 to 2005, the average annual demand for automobile body molds in China will be about 15 million man - hours, of which 9.36 million man-hours will be required for large and medium-sized molds. However, at present, China's large and medium-sized automobile mold production capacity is only 5.2 million man-hours per year, with a shortage of 4.36 million man-hours per year, and the satisfaction rate is only 53.4 %.
Plastic part mould. Driven by the trend of lightweight body, the application of plastics in automobiles has increased significantly, with the number of plastic parts and total weight of each automobile rising continuously. According to the calculation of the annual output of 3 million vehicles in 2005, China needs 300,000 tons of all kinds of plastic parts for automobiles, while the current production capacity is only 200,000 tons, and there is a great contradiction between production and demand. In particular, the large and medium-sized plastic molds required for manufacturing bumpers, instrument panels, fuel tanks, steering wheels, etc. are expected to meet only about 50 % of the planned demand in 2005.
Motorcycle mould. A motorcycle of one model needs nearly 1000 sets of moulds, worth more than 10 million yuan. China is already the world's largest motorcycle producer, with an annual output of more than 10 million motorcycles. Although most of the moulds for motorcycles can be produced in China, efforts should be made to nationalize the castings. Mould for agricultural vehicles. In the past, the mold industry did not pay enough attention to the molds of agricultural vehicles. In recent years, China's agricultural vehicle market has developed rapidly, with an annual output of more than 2 million vehicles, and the demand for molds has grown rapidly. At the same time, with the development of agricultural vehicles towards comfort, higher requirements have also been put forward for molds. During the " Tenth Five - Year Plan" period, the auto mold industry must pay enough attention to this market.
Conclusion
On the whole, China's low-tech molds are already in short supply and the market profit margin is narrow. However, the medium and high-grade molds with high technical content are still far from meeting the needs of economic development, and there is still much room for development of high-grade molds such as precision and complex dies and car cover molds. The future development direction of China's automobile mould industry should focus on the adjustment and positioning of product structure. To further improve the level of mold manufacturing technology and occupy the high-grade mold market with complex structure, high precision and high technical content.
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